Lime causticization product brightness improvement via pre-slaking

ABSTRACT

A method for obtaining particulate calcium carbonate exhibiting improved brightness and color and having uniformity of size such that when the particles are formed in the causticization process in a kraft pulp mill, the time required to separate the particles from liquors in which they are suspended is minimized and the amount of liquor recovered is maximized, with minimal dilution by water used for washing. The method includes the steps of a) slaking calcium oxide in water or an alkaline liquor containing as dissolved species predominantly sodium hydroxide; b) mixing the slaked lime with green liquor from a kraft pulping process to complete a causticization reaction that produces white liquor and lime mud; c) separating the lime mud from the white liquor; and d) milling a portion of the lime mud for use as a white mineral pigment in applications where such pigments are typically used.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a 35 U.S.C. § 371 national stage application ofInternational application number PCT/US2011/048426, filed on 19 Aug.2011, and published as WO 2012/027223 A1 on 1 Mar. 2012, which claimsthe benefit of U.S. provisional patent application No. 61/376,440, filedon 24 Aug. 2010.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates in general to methods for obtainingparticulate calcium carbonate, and more particularly to methods forobtaining particulate calcium carbonate having uniformity of size suchthat when the particles are formed in the causticization process in akraft pulp mill, the time required to separate the particles fromliquors in which they are suspended is minimized and the amount ofliquor recovered is maximized, with minimal dilution by water used forwashing. Such uniformity of size also tends to improve the brightnessand color of the particulate calcium carbonate.

2. Background of the Art

The kraft process, also known as the sulfate process, for extractingcellulose pulp from wood is practiced throughout the world. In manymills, the process is done in a sequential, closed loop that includesrecovery of the spent chemicals. There are three (3) main operations inkraft pulping, and these are shown in FIG. 1.

-   -   a. Pulping, in which wood chips are cooked in a chemical        solution, called white liquor, that consists primarily of        caustic soda (NaOH) and sodium sulfide (Na₂S).    -   b. Black Liquor Evaporation & Combustion, in which water is        first removed from the spent cooking liquor followed by        combustion to produce energy and recover non-combustible        inorganic chemicals. The chemicals are recovered in a molten        state, called a smelt, and dissolved in a dilute aqueous        solution called weak wash that is produced in another part of        the process. The dissolved smelt is called green liquor. The        primary species in green liquor are sodium carbonate (Na₂CO₃),        sodium sulfide (Na₂S) and sodium hydroxide (NaOH). The        characteristic color of green liquor is due primarily to the        presence of insoluble organic and inorganic sulfides, which are        compounds containing sulfur in a chemically reduced state.    -   c. Causticization (sometimes called re-causticization), is a        process where green liquor is combined with, or causticized,        with lime (CaO). Causticization regenerates white liquor, along        with particulate calcium carbonate, called lime mud. The lime        mud is discharged to a landfill or fed to a mud kiln to where it        is calcined to re-generate lime for causticization.

The causticization reactions can be writtenCaO+H₂O→Ca(OH)₂  (1)Ca(OH)₂+Na₂CO₃→2NaOH+CaCO₃  (2)

Note that in Equation (2), sodium is being exchanged with calcium. Thisis observed in FIG. 1, where the two process loops depicted are labeledthe Sodium Loop and the Calcium Loop, and the intersection of the loopsoccurs in the causticization step. Maximum chemical efficiency andminimal material losses occur when sodium and calcium are contained ascompletely as possible within their respective loops, with as littleexchange as possible of either element (Na or Ca) into the opposingloop. Note also that sodium sulfide (Na₂S), which is necessary to thepulp cooking process, does not participate in the causticizationreaction, but is simply transferred from green liquor to white liquor asthe causticization reaction proceeds.

In conventional kraft pulping, causticization is done by continuouslyfeeding a stream of dry calcium oxide powder into a slaker into which issimultaneously and continuously fed a stream of green liquor. Under suchconditions, Reactions 1 and 2 occur in quick succession, beginning inthe slaking vessel and continuing over a period of hours as the reactionmixture is fed to a series of causticization tanks. The residence timein the causticization tanks is determined by the flow rates and is setsuch that the reaction is essentially complete when the mixture exitsthe last tank in the series. Multiple stirred tanks fed by gravity flowtypically are used, and this ensures good mixing of the reactantsthroughout the process. By carrying out Reactions 1 and 2 via asingle-step addition, large, highly agglomerated particles are formedwhich are easily separated from the white liquor that is co-produced.

Surprisingly, it has been found that by carrying out the reactionsdefined by Equation 1 and 2 in separate steps, an improved uniformity ofsize of the lime mud particles is achieved. The degree of agglomerationis correspondingly reduced as well, while maintaining ease of separationof lime mud from white liquor. Even more surprisingly, although theaverage size of the lime mud particles may be reduced in the process ofthe current invention (i.e., the particles may, on average, becomesmaller) the improved particle uniformly and reduced agglomerationresult in an increase in the rate of separation of the particles fromthe white liquor. Along with these benefits, brightness and color of thelime mud particles are improved as well.

The process of the current invention thus produces a brighter, moreuniform material that is more suited to applications in which whiteminerals are typically used. Greater uniformity of particles requiresless energy, for example, when milling is used to reduce the size of theparticles for those applications that require it.

A kraft causticization process that does not employ a mud kiln isdepicted in FIG. 2. In FIG. 2, lime (CaO) that is purchased and storedin a silo is fed to a slaker where it is combined with a stoichiometricexcess of filtered green liquor. The mixture from the slaker is fedsequentially to a series of causticization tanks that are filled bygravity overflow. The tanks provide sufficient residence time for thereaction between lime and green liquor to proceed as nearly tocompletion as possible.

The slurry from the causticization tanks is fed to a filter where thewhite liquor and lime mud are separated. The time required forfiltration and the efficiency of separation are determined largely bythe size and size distribution of the lime mud particles. It isgenerally desirable that the particles be of sufficiently large size toprovide fast and substantially complete separation from the whiteliquor.

Following separation from the white liquor, the concentrated lime mud isfed to a mud wash filter where it is washed with water to remove whiteliquor that remains trapped in the filter cake. Again, it is generallydesirable that the particles are sufficiently large and distributed overa narrow range of sizes so as to minimize the amount of water consumedin washing. The diluted white liquor, or weak wash, recovered duringthis step is returned to the black liquor recovery boiler where it isused to dissolve smelt to form green liquor.

The washed lime mud can be treated by passing a stream of vaporizedcarbon dioxide (CO₂) through the lime mud to convert any remainingsodium hydroxide (NaOH) to sodium carbonate/sodium bicarbonate(Na₂CO₃/NaHCO₃) thus rendering the pH of the mud sufficiently low as tobe safely discharged to landfill. FIGS. 1 and 2 serve to illustrateseveral operational issues that can reduce the overall efficiency of therecovery process or create problems in disposing of the lime mud, eitherin a landfill or by calcination in a mud kiln.

First, incomplete separation of sodium compounds can occur when lime mudis separated from white liquor following causticization. Material lossof sodium from the sodium loop represents a cost, as any lost sodiummust be replaced. FIG. 1 shows that makeup chemicals are often added tothe black liquor recovery boiler where they become part of the smelt.

Also, sodium species that remain with the lime mud must either beremoved from the mud via washing or remain with the mud. Kraft processesthat employ a mud kiln generally operate to obtain a certain desirablelevel of sodium in the kiln feed, as this aids in the formation ofnodular aggregates that are more efficiently calcined than fine powders.However, too much sodium in the mud leads to the formation of kiln ringsthat slow or stop the transport of material through the kiln. When theyoccur, kiln rings must be removed, which requires shutdown and coolingof the kiln and represents a significant operational inefficiency.Undesirably high sodium levels in the mud must therefore be reduced bywashing, which can lead to high water consumption, which is botheconomically and environmentally unsound.

Also, lime mud, which is chemically precipitated during thecausticization reaction, is highly suited to trapping and entrainingso-called non-process elements (NPEs) which are typically the metalsulfides of elements such as iron (Fe), magnesium (Mg), manganese (Mn)and others. In a kraft process employing a mud kiln, NPEs can build upin the system and must be periodically purged from the system bydischarging lime mud in order to maintain process efficiency. Suchpurging results in an increased amount of lime mud being discharged thanwould otherwise be required and represents an economic penalty.

Also, lime mud is typically light gray to dark gray in color due to thepresence of sulfides. In a kraft process that does not employ a mudkiln, dark lime mud caused by sulfides can result in a diminishedability to utilize the lime mud in applications that are generallysuited to the use of conventional calcium carbonate particles. Suchapplications include paper, paints, plastics, agricultural and otheruses. Additionally, lime mud that is intended for use in theseapplications generally must be milled to a target size and/or specificsurface area, which requires energy. Therefore it is desirable that thelime mud particles be formed as aggregates, which aids in filtration,but which are easily broken apart.

It is therefore an object of the invention to improve the separation ofwhite liquor from lime mud by controlling the particle size, sizedistribution and specific surface area of the mud by controlling theconditions under which the causticization process is carried out in akraft pulp mill.

It is another object of the invention to optimize the recovery of sodiumspecies in the white liquor while minimizing the amount of waterrequired for washing.

It is another object of the invention to maximize the whiteness andbrightness of the lime mud produced from the causticization reaction.

It is another object of the invention to optimize the morphology of thelime mud so that it can be more easily milled to a desired final size,thus requiring less milling energy.

It is another object of the invention to reduce the energy consumed bythe operation of a mud kiln in kraft processes that employ such a kiln.This is accomplished by reducing the volume of mud that must be fed tothe kiln when the lime mud arising from the invention exhibits improvedcolor and brightness and/or shape, and a larger portion of the lime mudcan be used as a pigment in applications where such pigments aretypically employed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic representation of the pulping, black liquorevaporation and causticization processes.

FIG. 2 is a diagrammatic representation of the kraft causticizationprocesses in a mill that does not use a mud kiln.

FIG. 3 is a diagrammatic representation of the kraft causticization ofgreen liquor according to a first embodiment of the present invention.

FIG. 4 is a diagrammatic representation of the kraft causticization ofgreen liquor according to a second embodiment of the present invention.

FIG. 5 is a diagrammatic representation of the kraft causticization ofgreen liquor according to a third embodiment of the present invention.

FIG. 6 is a diagrammatic representation of the kraft causticization ofgreen liquor according to a fourth embodiment of the present invention.

FIG. 7 is a diagrammatic representation of the kraft causticization ofgreen liquor according to a fifth embodiment of the present invention.

FIG. 8 is a diagrammatic representation of the kraft causticization ofgreen liquor according to a sixth embodiment of the present invention.

FIG. 9 is a diagrammatic representation of the kraft causticization ofgreen liquor according to a seventh embodiment of the present invention.

FIG. 10 is a diagrammatic representation of the kraft causticization ofgreen liquor according to an eighth embodiment of the present invention.

FIG. 11 is an illustration showing the correlation between the surfacearea and filtration time of a control sample of ALBACAR® precipitatedcalcium carbonate, treated lime mud of the present invention and limemud from a typical kraft pulp mill.

FIG. 12 is a graph showing the correlation between brightness and sizeof particulate calcium carbonate of the present invention and from atypical kraft pulp mill.

FIG. 13 is a graph showing the correlation between filtration time andsize of particulate calcium carbonate of the present invention and froma typical kraft pulp mill.

DESCRIPTION OF THE INVENTION

The present invention comprises a method of obtaining particulatecalcium carbonate from the causticization process in a kraft pulp mill.The method comprises the steps of a) slaking calcium oxide (CaO, lime)in water or an alkaline liquor containing as dissolved speciespredominantly sodium hydroxide; b) mixing the slaked lime with greenliquor from a kraft pulping process to complete a causticizationreaction that produces white liquor and lime mud; c) separating the limemud from the white liquor; and d) milling a portion of the lime mud foruse as a white mineral pigment in applications where such pigments aretypically used.

In one embodiment of the present invention, the calcium oxide of step a)is first slaked in water to form milk of lime. The milk of lime is thenfed into a reactor containing kraft mill green liquor to complete acausticization reaction that produces white liquor and lime mud. Thelime mud and white liquor are separated, and the mud is washed withwater before a portion of the lime mud is milled for use as a whitemineral pigment in applications where such pigments are typically used.The washed lime mud can be treated at treatment means 170 by passing astream of vaporized carbon dioxide (CO₂) through the lime mud to convertany remaining sodium hydroxide (NaOH) to sodium carbonate/sodiumbicarbonate (Na₂CO₃/NaHCO₃).

In one embodiment of the present invention, shown in FIG. 3, the calciumoxide of step a) is first slaked in water to form milk of lime. The milkof lime is then fed into a reactor containing kraft mill green liquor tocomplete a causticization reaction that produces white liquor and limemud. The lime mud and white liquor are separated, and the mud is washedwith water before a portion of the lime mud is milled for use as a whitemineral pigment in applications where such pigments are typically used.The washed lime mud can be treated at treatment means 170 by passing astream of vaporized carbon dioxide (CO₂) through the lime mud to convertany remaining sodium hydroxide (NaOH) to sodium carbonate/sodiumbicarbonate (Na₂CO₃/NaHCO₃).

In another embodiment of the present invention as seen in FIG. 5, thecalcium oxide which can be stored in lime silo 310 of step a) is slakedat slaker 330 in weak wash generated when lime mud that has beenseparated such as by filtration by a filtration means, here mud washfilter 360 from white liquor is further washed with water to removeresidual white liquor from the mud cake. The slaked lime slurry is thenfed into a reactor containing kraft mill green liquor which can befiltered at green liquor filter 320 to complete a causticizationreaction that produces white liquor and lime mud. The causticizationreaction can occur in causticization tanks 340. The lime mud and whiteliquor are separated such as by filtration by a filtration means, herefilter 350, and the mud is washed at mud wash filter 360 with waterbefore a portion of the lime mud is milled for use as a white mineralpigment in applications where such pigments are typically used. Thewashed lime mud can be treated at treatment means 370 by passing astream of vaporized carbon dioxide (CO₂) through the lime mud to convertany remaining sodium hydroxide (NaOH) to sodium carbonate/sodiumbicarbonate (Na₂CO₃/NaHCO₃).

In another embodiment of the present invention as seen in FIG. 6, thecalcium oxide which can be stored in lime silo 410 of step a) is slakedat slaker 430 in white liquor produced by the causticization reaction ofa kraft pulping process.

The slaked lime slurry is then fed into a reactor containing kraft millgreen liquor which can be filtered at green liquor filter 420 tocomplete a causticization reaction that produces white liquor and limemud. The causticization reaction can occur in causticization tanks 440.The lime mud and white liquor are separated such as by filtration by afiltration means, here filter 450, and the mud is washed at mud washfilter 460 with water before a portion of the lime mud is milled for useas a white mineral pigment in applications where such pigments aretypically used. The washed lime mud can be treated at treatment means470 by passing a stream of vaporized carbon dioxide (CO₂) through thelime mud to convert any remaining sodium hydroxide (NaOH) to sodiumcarbonate/sodium bicarbonate (Na₂CO₃/NaHCO₃).

In another embodiment of the present invention, the causticizationreaction between kraft green liquor and milk of lime or lime hydrate oralkaline slurry of lime in white liquor or weak wash is donecontinuously.

In another embodiment of the present invention, the causticizationreaction between kraft green liquor and milk of lime or lime hydrate oralkaline slurry of lime in white liquor or weak wash is done in a batchreactor.

In another embodiment of the present invention as seen in FIG. 7, thecalcium oxide which can be stored in lime silo 510 of step a) is slakedat slaker 530 in white liquor produced by the causticization reaction ofa kraft pulping process. The slaked lime slurry is then fed into astream or volume of white liquor before being subsequently fed into areactor containing kraft mill green liquor which can be filtered atgreen liquor filter 520 to complete a causticization reaction thatproduces white liquor and lime mud. The causticization reaction canoccur in causticization tanks 540. The lime mud and white liquor areseparated such as by filtration by a filtration means, here filter 550.A portion of the white liquor from filter 550 can be the white liquorinto which slaked lime slurry is fed. The mud is washed at mud washfilter 560 with water before a portion of the lime mud is milled for useas a white mineral pigment in applications where such pigments aretypically used. The washed lime mud can be treated at treatment means570 by passing a stream of vaporized carbon dioxide (CO₂) through thelime mud to convert any remaining sodium hydroxide (NaOH) to sodiumcarbonate/sodium bicarbonate (Na₂CO₃/NaHCO₃).

In another embodiment of the present invention as seen in FIG. 8, limehydrate powder which can be stored in lime hydrate storage tank 675 iscombined with a stream or volume of white liquor before beingsubsequently fed into a reactor containing kraft mill green liquor whichcan be filtered at green liquor filter 620 to complete a causticizationreaction that produces white liquor and lime mud. The causticizationreaction can occur in causticization tanks 640. The lime mud and whiteliquor are separated which can occur by means of a filter 650. A portionof the white liquor from filter 650 can be the white liquor into whichslaked lime slurry is fed. The mud is washed at mud wash filter 660 withwater before a portion of the lime mud is milled for use as a whitemineral pigment in applications where such pigments are typically used.The washed lime mud can be treated at treatment means 670 by passing astream of vaporized carbon dioxide (CO₂) through the lime mud to convertany remaining sodium hydroxide (NaOH) to sodium carbonate/sodiumbicarbonate (Na₂CO₃/NaHCO₃).

In another embodiment of the present invention as seen in FIG. 9, thecalcium oxide which can be stored in lime silo 710 of step a) is slakedat slaker 730 in water. The slaked lime is then fed into a stream orvolume of white liquor before being subsequently fed into a reactorcontaining kraft mill green liquor which can be filtered at green liquorfilter 720 to complete a causticization reaction that produces whiteliquor and lime mud. The causticization reaction can occur incausticization tanks 740. The lime mud and white liquor are separatedwhich can occur by means of a filter 750. A portion of the white liquorfrom filter 750 can be the white liquor into which slaked lime slurry isfed. The mud is washed with water at mud wash filter 760 before aportion of the lime mud is milled for use as a white mineral pigment inapplications where such pigments are typically used. The washed lime mudcan be treated at treatment means 770 by passing a stream of vaporizedcarbon dioxide (CO₂) through the lime mud to convert any remainingsodium hydroxide (NaOH) to sodium carbonate/sodium bicarbonate(Na₂CO₃/NaHCO₃). In another embodiment of the present invention shown inFIG. 10, the calcium oxide which can be stored in lime silo 810 of stepa) is slaked at slaker 830 in weak wash generated when lime mud that hasbeen separated at filter 850 from white liquor is further washed withwater to remove residual white liquor from the mud cake. The slake isthen fed into a stream or volume of white liquor before beingsubsequently fed into a reactor containing kraft mill green liquor whichcan be filtered at green liquor filter 820 to complete a causticizationreaction that produces white liquor and lime mud. The causticizationreaction can occur in causticization tanks 840. The lime mud and whiteliquor are separated at filter 850. A portion of the white liquor fromfilter 850 can be the white liquor into which lime slurry which wasslaked in weak wash is fed. The mud is washed with water at mud washfilter 860 before a portion of the lime mud is milled for use as a whitemineral pigment in applications where such pigments are typically used.The washed lime mud can be treated at treatment means 870 by passing astream of vaporized carbon dioxide (CO₂) through the lime mud to convertany remaining sodium hydroxide (NaOH) to sodium carbonate/sodiumbicarbonate (Na₂CO₃/NaHCO₃).

EXAMPLES Example 1

This Example is intended to be a comparative example carried outaccording to conventional means and not according to the method of thecurrent invention.

To a 4-liter SS reactor were added 1850 ml of kraft green liquorfiltered through No. 4 Whatman filter paper and comprised of, asdissolved species, 12.54 wt. % sodium carbonate (Na₂CO₃), 2.36 wt. %sodium sulfide (Na₂S) and 1.59 wt. % sodium hydroxide (NaOH), and havinga specific gravity of 1.21. The contents of the reactor were then heatedto 95° C. and held at that temperature by means of a circulating bathcontaining a 1:1 mixture of ethylene glycol and water. Agitation wasaccomplished by means of an impeller rotating at 1000 rpm.

100 g of granular lime having an active CaO content of about 95% wasadded to the reactor over about 15 seconds, and the maximum temperature(T_(max)) in the reactor was recorded as 102° C.

The mixture in the reactor was held at 95° C. under agitation for 180minutes before passing the contents over a 100 mesh screen followed byfiltration through No. 4 Whatman filter paper to separate the whiteliquor from the lime mud. The lime mud filter cake was washed with tapwater until the conductivity of the effluent stream was measured as <1mS. The ISO (R₄₅₇) dry brightness of the washed cake was 85.8, CIE b*was 0.91 and BET Specific Surface Area (SSA) was 4.1 m²/g.

Example 2

This Example was carried out according to the process of the currentinvention. To a 4-liter SS reactor were added 1850 ml of the filteredkraft green liquor of Example 1. The contents of the reactor were thenheated to 95° C. and held at that temperature by means of a circulatingbath containing a 1:1 mixture of ethylene glycol and water. Agitationwas accomplished by means of an impeller rotating at 1000 rpm.

To a 1-liter SS beaker containing 500 g of water at an initialtemperature of 76° C. were added 100 g of the granular lime ofExample 1. Slaking was carried out for 15 minutes under agitation bymeans of an impeller rotating at 1000 rpm. T_(max) was recorded as 100°C. after about 1 minute.

The contents of the SS beaker were then poured into the SS reactor overabout 1 minute at which time the temperature in the reactor dropped toabout 92° C. before rising to 95° C. over about 5 minutes. The contentsof the reactor were then agitated at temperature for 180 minutes beforepassing the contents over a 100 mesh screen followed by filtrationthrough No. 4 Whatman filter paper to separate the white liquor from thelime mud. The lime mud filter cake was washed with tap water until theconductivity of the effluent stream was measured as <1 mS. The ISO(R₄₅₇) dry brightness of the washed cake was 91.8, CIE b* was 1.13 andBET SSA was 4.3 m²/g.

Example 3

This is another Example carried out according to the process of thecurrent invention.

To a 4-liter SS reactor were added 1850 ml of kraft green liquorfiltered through No. 4 Watman filter paper and comprised of, asdissolved species, 12.54 wt. % sodium carbonate (Na₂CO₃), 2.36 wt. %sodium sulfide (Na₂S) and 1.59 wt. % sodium hydroxide (NaOH). Thecontents of the reactor were then heated to 95° C. and held at thattemperature by means of a circulating bath containing a 1:1 mixture ofethylene glycol and water. Agitation was accomplished by means of animpeller rotating at 1000 rpm.

To a 1-liter SS beaker containing 500 g of kraft mill white liquorcomprised of, as dissolved species, 8.04 wt. % sodium hydroxide (NaOH),1.93 wt. % sodium carbonate (Na₂CO₃) and 1.89 wt. % sodium sulfide(Na₂S), and having a specific gravity of 1.15 at an initial temperatureof 77° C. were added 100 g of the granular lime of Example 1. Slakingwas carried out for 15 minutes under agitation by means of an impellerrotating at 1000 rpm. T_(max) was recorded as 104° C. after about 2minutes.

The contents of the SS beaker were then poured into the SS reactor overabout 1 minute at which time the temperature in the reactor dropped toabout 92° C. before rising to 96° C. over about 5 minutes. The contentsof the reactor were then agitated at temperature for 180 minutes beforepassing the contents over a 100 mesh screen followed by filtrationthrough No. 4 Whatman filter paper to separate the white liquor from thelime mud. The lime mud filter cake was washed with tap water until theconductivity of the effluent stream was measured as <1 mS. The ISO(R₄₅₇) dry brightness of the washed cake was 92.3, CIE b* was 1.31 andBET SSA was 3.1 m²/g

Example 4

This is another Example carried out according to the process of thecurrent invention.

To a 4-liter SS reactor were added 500 g of the kraft white liquor ofExample 3 which were heated to 95° C. and held at that temperature bymeans of a circulating bath containing a 1:1 mixture of ethylene glycoland water. Agitation was accomplished by means of an impeller rotatingat 1000 rpm.

To a glass 4-liter reactor were added 2238 g of the green liquor ofExample 1 which were heated to 75° C. using an electric heating mantle.

To a glass 2-liter reactor were added 500 g of the kraft white liquor ofExample 3 which were heated to 70° C. using an electric heating mantle.The heating mantle was turned off and 100 g of the lime from Example 1were added to the heated white liquor under agitation provided by animpeller rotating at 700 rpm. Tmax was 98° C. after about 3 minutes.After about 20 minutes, the electric mantle was again turned on. At thistime, alkaline slurry of lime in white liquor had cooled to about 85° C.

The alkaline slurry of lime in white liquor was pumped at a rate of 17.7ml/min into the 4-liter SS reactor containing the heated white liquor.Simultaneously, green liquor was pumped at a rate of 62.0 ml/min intothe 4-liter SS reactor. As the slurry and green liquor were added,agitation was accomplished by means of an impeller rotating at 1000 rpm.Addition of the slurry and green liquor was complete after about 27minutes during which time the temperature of the reactor contents rosefrom about 92 to about 94° C. Mixing was continued for about 20 minutesbefore passing the contents of the SS reactor over a 100 mesh screenfollowed by filtration through No. 4 Whatman filter paper to separatethe white liquor from the lime mud. The lime mud filter cake was washedwith tap water until the conductivity of the effluent stream wasmeasured as <1 mS. The ISO (R₄₅₇) dry brightness of the washed cake was90.9, CIE b* was 1.22 and BET SSA was 1.2 m²/g.

As can be seen in the above Examples 2, 3 and 4 made according to thepresent invention, the ISO(R₄₅₇) dry brightness of the washed lime mudfilter cake or particulate calcium carbonate was above 90 in each case.Further in each of these three above-mentioned examples, a CIE b* valuewas achieved for the precipitated calcium carbonate which is acceptablefor papermaking.

Examples 5-10

These Examples were carried out according to conventional means and notaccording to the method of the current invention. A series of reactionswere carried out, each reaction done according to the same process thatis described below. The results are recorded in Table 1.

To a 4-liter reactor were added 1850 ml of kraft green liquor filteredthrough No. 4 Whatman filter paper and comprised of, as dissolvedspecies, 12.54 wt. % sodium carbonate (Na₂CO₃), 3.36 wt. % sodiumsulfide (Na₂S) and 1.59 wt. % sodium hydroxide (NaOH), and having aspecific gravity of 1.21. The contents of the reactor were then heatedto 95° C. and held at that temperature by means of a circulating bathcontaining a 1:1 mixture of ethylene glycol and water. Agitation wasaccomplished by means of an impeller rotating at 1000 rpm.

100 g of granular lime having an active CaO content of about 95% wasadded to the reactor over about 15 seconds.

The mixture in the reactor was held at 95° C. under agitation for 180minutes before passing the contents over a 100 mesh screen followed byfiltration through No. 4 Whatman filter paper to separate the whiteliquor from the lime mud. The lime mud filter cake was washed with tapwater until the conductivity of the effluent stream was measured as <1mS. The particle size distribution of the lime mud particles wasmeasured using a Micromeritics Sedigraph 5100. The Hunter brightness andcolor of the washed, wet cake were recorded as was the ISO (R₄₅₇) drybrightness and BET Specific Surface Area (SSA).

TABLE 1 WASHED SLURRY TESTING OVEN DRY Hun- Filtration TESTING d₉₀, d₅₀,Hunter ter rate SSA, ISO CIE μm μm Rd b (sec) m²/g R₄₅₇ b* Example 516.7 6.0 27.4 −1.3 29 2.9 70.8 2.4 Example 6 12.7 4.3 34.9 −1.0 35 4.177.6 1.7 Example 7 13.3 4.7 38.2 −1.2 35 3.7 76.7 1.3 Example 8 13.6 4.833.7 −1.3 30 4.0 74.6 1.9 Example 9 12.3 4.4 38.9 −1.3 31 4.2 79.7 1.2Example 10 14.4 4.7 36.0 −1.0 25 5.7 77.3 1.2

Examples 11-15

These Examples were carried out by the method of the current invention.A series of reactions were carried out, each reaction done according tothe conditions described in Example 3, but using a green liquorcontaining the same dissolved species in the same concentrations as usedin Examples 5-10. The results are recorded in Table 2.

TABLE 2 WASHED SLURRY TESTING OVEN DRY Filtration TESTING d₉₀, d₅₀,Hunter Hunter rate SSA, ISO CIE μm μm Rd b (sec) m²/g R₄₅₇ b* Example 114.5 2.9 40.7 -0.6 32 3.1 88.0 2.6 Example 12 4.7 3.1 37.4 -0.4 23 3.187.1 2.7 Example 13 5.3 3.4 33.9 -0.5 22 3.4 81.0 1.9 Example 14 4.0 2.558.8 0.1 29 3.9 92.3 1.4 Example 15 4.8 3.1 49.2 -0.1 30 3.3 89.8 1.5

The data contained in Tables 1 and 2 are compared in FIGS. 12 and 13,and serve to illustrate the differences among lime mud particlesproduced via conventional means and lime mud particles producedaccording to the method of the current invention.

In FIG. 12 it is evident that lime mud particles arising from the methodof the current invention exhibit sizes about one-half that of particlesarising from conventional causticization. This in turn gives rise tohigher brightness. It is both counterintuitive and surprising to observethe data shown in FIG. 13.

The filtration data shown in FIG. 13 was obtained from a laboratoryfiltration test designed to standardize and measure the time required toseparate small amounts of lime mud from the free liquid in which theparticles of lime mud are suspended. The test is done as follows:

-   -   1. A 5.5 cm Buchner funnel is connected to a sidearm flask under        water aspiration and fitted with w/Whatman No. 5 filter paper.    -   2. 50 g of 20±1% solids of slurry that has first been        water-washed to ≤1 mS conductance in the effluent is well-shaken        and instantly poured into the Buchner funnel.    -   3. The time (in seconds) until there is no visible liquid on top        of the cake is recorded.

FIG. 13 clearly shows that although the particles produced by the methodof the current invention are smaller than those produced viaconventional means, they also are more easily separated from the liquidin which they are suspended, as evidenced by filtration times that areequal or lower than for particles produced by conventional processes.

Accordingly, by the method of the present invention a particulatecalcium carbonate suitable for paper can be made. Paper can be madecomprising the particulate calcium carbonate made by the method of thepresent invention.

Paper can be made comprising pulp made by chemical pulping such as theKraft process and also comprising particulate calcium carbonate made bythe method of the present invention.

Accordingly, it is understood that the above description of the presentinvention is susceptible to considerable modifications, changes andadaptations by those skilled in the art, and that such modifications,changes and adaptations are intended to be considered within the scopeof the present invention.

We claim:
 1. A method for obtaining particulate calcium carbonateproduct comprising: providing green liquor from a kraft pulping process;adding calcium oxide to a fluid to form a reaction product of calciumoxide and the fluid; agitating the reaction product of calcium oxide andthe fluid; after agitation, optionally adding white liquor from a kraftpulping process to the reaction product of calcium oxide and the fluid;after the agitation and the optional addition of white liquor, reactingthe reaction product of calcium oxide and the fluid, optionallycomprising added white liquor, with the green liquor to complete acausticization reaction which produces white liquor and unwashed limemud comprising calcium carbonate; separating the unwashed lime mud fromthe white liquor; washing the unwashed lime mud with water to providewashed lime mud and weak wash; and reacting the washed lime mud withcarbon dioxide vapor; wherein the fluid to which the calcium oxide isadded is weak wash or a combination of water and weak wash; wherein theweak wash is weak wash from washing the lime mud with water; and whereina portion of the white liquor from the causticization reaction is thewhite liquor which is optionally added after the agitation.
 2. Themethod of claim 1, wherein after agitation, white liquor is added, suchthat a portion of the white liquor from the causticization reaction isthe white liquor added after the agitation.
 3. The method of claim 1,wherein separating the lime mud from the white liquor comprises use of aWhatman no. 4 filter.
 4. The method of claim 1, wherein the agitationoccurs for at least 15 minutes.
 5. A method for obtaining particulatecalcium carbonate product comprising: providing green liquor from akraft pulping process; slaking calcium oxide in a fluid comprising waterto form a milk of lime; reacting the milk of lime with the green liquorto complete a causticization reaction which produces white liquor andunwashed lime mud comprising calcium carbonate; and separating the limemud from the white liquor, washing the lime mud with water to providewashed lime mud, and reacting the washed lime mud with carbon dioxidevapor; wherein the fluid in which the calcium oxide is slaked is weakwash or a combination of water and weak wash, the weak wash being weakwash from washing lime mud with water.
 6. The method of claim 5, inwhich slaked calcium oxide is combined with white liquor from a kraftpulping process and the combination is reacted with the green liquorfrom a kraft pulping process, wherein a portion of the white liquor fromthe causticization reaction is the white liquor which is combined withthe slaked calcium oxide.
 7. The method of claim 5, comprising combiningthe slaked calcium oxide with white liquor from a kraft pulping process;reacting the combination of slaked calcium oxide and white liquor withthe green liquor from a kraft pulping process.